Reusable Container

ABSTRACT

A collapsible container for stackable items can comprise a hollow cylinder of a resilient material. The cylinder can be open at both ends and can include a retainer at each end. The cylinder can have a plurality of lines of weakness extending along at least a portion of the length of the cylinder such that the container can be collapsed by application of a nominal force.

RELATED APPLICATION

This application is related to, and claims benefit under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 60/822,170, filed on Aug. 11, 2006, the entirety of which is hereby incorporated by reference herein and made a part of the present disclosure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to collapsible containers, and more particularly to reusable collapsible containers.

2. Description of the Related Art

Commercial coin containers are used by banks and stores for storing and transporting coins. These institutions mainly rely on disposable coin containers such as paper wrappers that are wrapped around the coin stack several times and which have wide end margins that can be subsequently crimped. Other institutions use “shrink-wrap” plastic wrappings that are thermally compounded to shrink tightly about the coins when heated.

U.S. Pat. No. 5,595,338 entitled “Reusable Container For A Stack Of Coins,” which is hereby incorporated by reference herein in its entirety, discloses a reusable collapsible coin containers that is formed from flexible plastic lay-flat tubing. While the container of the '338 patent represents a significant advancement in the art, there remains a general desire to improve the manufacturability and usability of such a reusable container.

SUMMARY OF THE INVENTION

Accordingly, an aspect of at least one of the embodiments disclosed herein includes the realization that the production of collapsible containers from lay-flat tubing requires multiple steps, namely, blowing thin-walled tubing, running the narrow-gauge tubing through pinch rollers at high speed, and subsequently winding the material onto cores for storage and later secondary processing via narrow web rotary press. The winding of the material onto cores for storage awaiting subsequent operations is due to the internal economics of plastic extruders who use their equipment 24 hours a day, seven days a week for the manufacture of many types of tubing for many different customers, and generally sell their services on the basis of machine hours. Aside from the additional cost of handling and warehousing lay-flat tubing, an unacceptable consequence of wound storage can be that the lay-flat tubing develops a permanent “core-set,” which greatly complicates secondary manufacturing operations. Once the container has been singulated from the narrow web of lay-flat tubing, the eccentric wall thickness of blown film and core-set from storage may inhibit or complicate one or more subsequent operations, such as flattening of the tube, opening of the tube, and/or proper operation of toggles. Additionally, the use of recyclates, i.e., post-consumer or post-industrial plastic, is not viable in thin-wall extrusions. The impurities of recyclates, combined with their unknown and variable heat history, do not support blown-film extrusion of lay-flat tubing.

Thus, in accordance with at least one of the embodiments disclosed herein, a collapsible container for stackable items comprises a hollow cylinder of a resilient material, open at both ends, including at each end a retainer. The cylinder has a plurality of lines of weakness extending along at least a portion of the length of the cylinder such that the container is collapsible by application of a nominal force.

In accordance with at least one of the embodiments disclosed herein a collapsible container for storage of one or more objects comprises a plurality of longitudinal segments interconnected by compliant hinges. The longitudinal segments and compliant hinges form a loop. The loop has a passage extending between first and second openings. The loop has a first configuration permitting storage of objects within the passage and a second configuration wherein the cross-sectional area of the passage is reduced. The collapsible container further comprises a retainer near each of the first and second openings. Each retainer has an open position to allow objects to pass through one of the first and second openings into the passage and a closed position to inhibit movement of objects within the passage from moving out of the passage.

All of these embodiments are intended to be within the scope of the present invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features of the invention disclosed herein are described below with reference to the drawings of the preferred embodiments. The illustrated embodiments are intended to illustrate, but not limit, the invention. The drawings contain the following figures:

FIG. 1 is a perspective view of an embodiment of a collapsible container in an expanded configuration.

FIG. 2 is a perspective view of the collapsible container of FIG. 1 in a collapsed configuration.

FIG. 3 is a perspective view of an embodiment of a collapsible container in a collapsed configuration.

FIG. 4 is a perspective view of an embodiment of a collapsible container in a collapsed configuration.

FIG. 5 is a top view of the collapsible container of FIGS. 1 and 2.

FIG. 6 is an end view of the collapsible container of FIGS. 1, 2, and 5 with the toggles in an open position.

FIG. 7 is an end view of the collapsible container of FIGS. 1, 2, 5, and 6 with the toggles in a closed position.

FIG. 8 illustrates an arrangement of mechanical actuators to open and close a pair of toggles according to one embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates one embodiment of a collapsible container 100 that can be used in a variety of applications, including, for example, handling, storage, and/or transportation of coins by banks and stores. The collapsible container 100 of FIG. 1 and other embodiments described herein can also be used for handling, storage, and/or transportation of other types of currency, such as transit tokens or casino chips. Other similarly-shaped items, including industrial components such as RFID tags and ceramic pills, may also be handled, stored, and/or transported in collapsible containers of the type disclosed herein. Additionally, collapsible containers may be useful for the temporary packaging of other small stackable goods, including throat lozenges, candy wafers, washers, soap disks, etc. Although the collapsible containers can have particularly utility in conjunction with items that are either cylindrical and/or stackable, the collapsible containers of the type disclosed herein can also be used in conjunction with items that are neither stackable nor cylindrical.

With reference to FIG. 1, the container 100 can include a plurality of longitudinal segments 102 connected by hinges 104 to create a cylinder 106. The cylinder 106 has an interior surface 110 and exterior surface 112. The interior surface 110 defines a passage 116 extending between the openings 108 at each of the ends 114. The container 100 can further comprise one or more retainers 118 at or near either one or both of the ends 114 of the cylinder 106.

The illustrated embodiment of the container 100 comprises six longitudinal segments 102 connected by six longitudinal hinges 104. However, it is anticipated that the number of longitudinal segments 102 and hinges 104 can be greater than six or can comprise as few as two. For example, a container 200, illustrated in FIG. 3, comprises four longitudinal segments 202 connected by four hinges 204. FIG. 4 illustrates a container 300 that comprises eight longitudinal segments 302 connected by eight hinges 304. As noted above, additional embodiments can comprise other numbers of longitudinal segments and hinges. For example, a container can comprise 10, 12, 14, 16 or more longitudinal segments. Although the illustrated embodiments comprise an even number of longitudinal segments, some embodiments comprise an odd number of longitudinal segments, such as 3, 5, 7 or more segments.

The longitudinal segments and hinges illustrated in FIGS. 1-8 form a closed loop. Alternatively, the longitudinal segments and hinges can form an open loop having a fastener disposed on one or both free ends of the loop such that the free ends can be connected to form a cylinder similar to the cylinders 106, 206, and 306 illustrated in FIGS. 1-8. It should also be appreciated that although the longitudinal segments 102 are illustrated has having an arc-like or semi-circular shape, in modified embodiments, the longitudinal segments can have a flat or different shape such that the container 100 does not have a substantially circular cross-section.

The hinges 104 can be compliant or “living” hinges that are integrally formed with the longitudinal segments 106. In some embodiments, the compliant hinges may be integrally formed portions of the cylinder 106 having a reduced thickness compared to adjacent longitudinal sections, thereby forming lines of weakness or increased or preferentially flexibility between adjacent longitudinal segments. Alternatively, lines of weakness or increased/preferential flexibility may be formed using perforations or by other techniques or arrangements known to those of skill in the art.

As illustrated in FIGS. 1 and 2, the hinges 104 can extend the substantially length of the cylinder 106. Alternatively, the hinges can extend less than substantially the entire length of the cylinder.

The inclusion of hinges 104 between longitudinal segments 102 advantageously facilitates collapsing or compression of the container 100. Preferably, the container 100 can be substantially flattened by a nominal applied force, such as finger pressure or the self-weight of containers 100 packaged in bulk. The nominal applied force can be 12 ounces or less, or alternatively equal to or more than 12 ounces. Flattening the container advantageously minimizes the space required during shipping and storage, and while containers are empty between reuses.

In one embodiment, the container 100 can be collapsed by application of a force in the general direction of arrows A, shown in FIG. 6, to place the container 100 in the collapsed or flattened configuration, shown in FIG. 2, thereby reducing or eliminating the cross-sectional of the passage 116. Additionally applied force, either momentary or prolonged, may substantially flatten the container 100 beyond the state shown in FIG. 2. Embodiments including longitudinal segments 102 that have an arcuate cross-section, as shown in FIG. 2 or other non-flat cross-sections, may be compressed into a flatter state by application of additional compressive force.

The container 100 can be expanded from the collapsed configuration, illustrated in FIG. 2, to the expanded configuration, illustrated in FIG. 1, by application of a force in the general direction of arrows B, shown in FIG. 2.

As noted above, the container 100 preferably comprises one or more retainers 118 at each of the openings 108. The retainers 118 can flip-top caps, bistable movable element or elements, or other retaining devices known to those of skill in the art, or a combination thereof.

In some embodiments, one or more of the retainers can comprise a bistable element or elements, such as a toggle, in which the mechanism has at least two stable equilibrium states within their range of motion and require no power input to remain stable at each equilibrium state. FIGS. 1-2 and 5-7 illustrate an embodiment including toggle-type retainers 118. The toggles 118 can comprise one or more arms 124 connected to the cylinder 106 by hinges 126. In the embodiment illustrated in FIGS. 1-2 and 5-7, each toggle 118 comprises two arms 124. However, the toggles can comprise other numbers of arms, for example, one arm or three arms. The arms 124 can also be connected by one or more intermediate hinges 128.

In some embodiments, the arms 124 can be marginal portions of the cylinder 106 and can have a cross-sectional shape similar to the longitudinal segments 102 to facilitate manufacture of the container 100. However, the shape retainers 118 need not approximate the cross-sectional shape of the longitudinal segments, nor must the retainers 118 be at the ends 114 of the cylinder 106. For example, the retainers 118 can be spaced inwardly from the ends 114 and/or have a shape different than the longitudinal segments 102. One such retainer may have one or more retainers between the ends 114 to retain contents in a container that is less than completely full.

The toggles 118 can be moved into a closed position, shown in FIG. 7, by applying a force generally along the arrows C, shown in FIGS. 5 and 6, to translate arms 124 via an over-the-center motion past the inflection point of the bistable mechanism and “snap” the toggle 118 closed in the opening 108 of the cylinder 106. By pinching the toggle arms 124 together at one end 114 of the container 100, the toggle arms 124 can provide a temporary retainer at one end 114 of the cylinder 106. This activation of the toggle arms 124 can also hold the cylinder 106 in the expanded configuration to prepare the container 100 for ingress of coins or other items from the opposing open end 114.

Once the contents are placed within the container 100, and optionally dimensionally counted, the toggle arms 124 at the opposing end can be closed to secure the contents within the container 100. Because the toggles 118 are bistable, translating through an over-the-center motion, they will not spring open until a counter-veiling force is applied.

While filled, the container can be stored or transported in vertical and/or horizontal positions. To release the contents, a force is applied between the toggles 118 generally along the arrows D, shown in FIG. 7, to translate the arms past their inflection point into the open configuration. To empty the contents of the container 100, the open end 114 of the container 100 can be aimed into a receptacle, such as a change drawer, and the contents may be rapidly expelled by gravity and/or a gentle shake of the container 100.

By opening all of the remaining closed toggles 118 in a similar fashion, the container can again assume a collapsed profile for storage, such as in a cash register. In the illustrated embodiments, the toggles 118 are preferably moved to their open position before the container 100 is collapsed to avoid damaging of the hinges 128.

The toggle arms 124 can be provided with textured areas 138, such as one or more ridges or grooves, to visually and/or tactilely aid manual users in locating the toggles 118 and/or developing muscle and sense memory. The textured areas 138 may facilitate proficient use in low light, or by the site impaired.

In some embodiments, the hinges 126 and/or 128 of the toggles 118 may be configured to prevent over-rotation of the hinges 126 and/or 128. In the embodiment illustrated in FIG. 7, the hinges 126 and 28 comprise stops or jambs 136 near to the hinges 126 and 128. The stops 136 can comprise angled surfaces located adjacent to or near the hinge's point of flexure or, alternatively or additionally, the stops 136 can be protrusions spaced apart from the point of flexure such that the hinges 126 and/or 128 come to rest against the stops simultaneously, thereby creating a “soft-stop” to prevent or reduce the likelihood of over-rotation of the hinges 126 and/or 128, which may lead to breakage of the hinges 126 and/or 128.

In some embodiments, adjacent longitudinal segments 102 can be offset from one another at or near one or more intervening hinges 104 of the container 100. For example, as illustrated in FIG. 6, the longitudinal segments 102 a can be offset from the longitudinal segments 102 b at hinges 104. The longitudinal segments 102 a and the longitudinal segments 102 b can be offset by approximately the thickness of one of the longitudinal segments 102, as illustrated in FIG. 6. In other embodiments, the offset between longitudinal segments 102 can be less than or greater than the thickness of one or more of the longitudinal segments 102.

The offset between the longitudinal segments 102 need not extend the entire length of the cylinder. Rather, in some embodiments the offset can extend only a portion of the length or the width of the cylinder 106 or of one or more of the longitudinal segments 102. Offsetting one or more longitudinal segments 102 can create a cam 120, a channel 122, or both (FIG. 6) that can extend all or a portion of the entire length of the container 100.

Offsetting the longitudinal segments 102 can provide one or more benefits, including allowing the toggle arms 124, which upon repeated use may relax slightly in the open position, to rest in the open position and not impede egress of the contents. Additionally, the channel 122 created by offsetting longitudinal segments 102 can reduce or eliminate suction lock of a stack of coins or other contents of the container 100. Also, the cam 120 created by offsetting longitudinal segments 102 can inhibit undesired rolling of the container 100 while in a horizontal orientation, such as when the container 100 is placed horizontally on a table.

The cam 120 can also facilitate rapid manipulation by mechanical means, such as suction devices for extending the cylinder 106 and mechanical actuators to move the retainers 118, to mechanically fill and/or empty the container 100 rapidly and effectively. Manipulability by mechanical means permits the collapsible containers to readily function as a cartridge for automated coin handling, such as is used in various casinos, banks, and coin centers.

For example, an orientation plate 130, shown in FIG. 8, can be used to orient the container 100 within an apparatus for mechanically filling and/or emptying the container 100. The orienting plate 130 can include an edge 132 that can abut the cam 120 of the container 100 to orient the container 100 within the mechanical apparatus.

Mechanical actuators 134 can also be used to move the toggles 118 between their open and closed positions. FIG. 8 illustrates an arrangement of a plurality of mechanical actuators 134 that can be used to move the toggles 118 between open and closed positions.

To close the container, the actuators 134 a, illustrated in an advanced position in FIG. 8, apply a force generally radially inwardly to close the toggle arms to thereby retain the contents of the container 100 therein. The actuators 134 b, illustrated in a retracted position in FIG. 8, can apply a force generally outwardly on the respective toggles 118, thereby moving the toggles 118 through an over-the-center motion to springing the toggles 118 clear of the opening releasing the contents.

The full throw of the actuators 134 needs only be sufficient to translate the toggle 118 over-the-center, or past the inflection point of the bistable mechanism. The resiliency of the plastic material will then translate the toggle arms 124 through their remaining range of motion when either opening or closing the toggles 118.

The container 100 may be made of any resilient material, such as thermoplastic resins or other resilient materials known to those of skill in the art, including other plastics and metals. Preferably, the container 100 is made of an injection-moldable material. For example, readily-available inexpensive grades of polypropylene resins can be used. Some embodiments employ compliant hinges and exploit the innate spring constant of thermoplastic materials.

The translucency of some plastic materials can also be exploited to give visual verification of the contents, which is especially important in money handling applications. In such embodiments, mono- or copolymer polypropylenes may be used because of their excellent hinge properties and translucency. Nonetheless, injection molding allows for use of a plurality of materials, some of which may be appropriate to special packaging applications. For example, anti-static plastic compounds may be desired for retaining electronic components, such as RFID tags, or high-density polyethylene for static control of ceramic pills.

Alternate resins may also be used to enhance the environmental benefits of reusable packaging. For example, post-industrial recyclates, post-consumer recyclates, and/or biodegradable organic plastics may be used. Hybrid materials, such as plastic and wood-flour compounds, may also be injection molded. These hybrid organic materials may be suitable for certain specialty packaging applications, such as “plantable” containers made from organic plastics and fertilizer compounds that self-compost to fertilize the small plants and seedlings as they decay underground.

In some embodiments, the container can be formed from a plurality of materials. For example, the container can be formed from first material that is opaque or translucent and from a second material that is transparent to allow the contents of the container to be viewed along the part or all of the length of the container. In other embodiments, one or more longitudinal segments 102 may be formed with one or more slots or other apertures to allow viewing of the contents of the container.

Embodiments of the collapsible container can be manufactured in a range of sizes relating, for example, to the dimensions of the world's coinage and the standard roll sizes used in international banking industries. Containers can also be made in sizes corresponding to other forms of currency, such as transit tokens and casino chips. Additionally, containers can be sized and shaped to accommodate industrial components, such as RFID tags and ceramic pills.

The thickness of the longitudinal segments 102 and the hinges 104 will vary proportionally with the size of the objects to be accommodated within the container 100 to and the desired mechanical action and operation of the retainers 118.

While various embodiments have been illustrated in having longitudinal segments having arcuate cross-sectional shapes, alternate embodiments can comprise longitudinal segments having other cross-sectional shapes, such as flat, faceted, parabolic or cross-sectional geometries. These alternate embodiments may yield a variety of cylindrical shapes, including triangular, hexagonal, octagonal, and other cylindrical shapes. These various shapes may be used for packaging small stackable goods, such as throat lozenges, candy wafers, washers, and soap disks.

In some embodiments, the collapsible containers may be manufactured by injection molding. Injection molding can advantageously allow commercially available resin pellets to be formed into a single finished product in a single step.

Injection-molded containers may benefit from priming the toggles 118 by moving them between their open and closed positions just after molding to better align the plastic molecules at the hinges and, thereby, increase the life cycle of the toggles. Such priming could be performed by the injection-mold-press operator between mold cycles, or by custom in-mold tooling, such as ejector/priming pins.

By altering the injection press's operating parameters, such as pressure, dwell, and temperature, the same tooling can be used with the plurality of thermoplastic resin as may be desired for alternate embodiments intended for monetary, industrial, and/or retail packaging. Post-consumer and post-industrial recyclates can also be injection molded, enabling greater environmental benefits and marketing advantages.

Additionally, some embodiments are reusable containers that do not require a formal reuse infrastructure, making it a rare example of a “waste source reduction” packaging. To further maximize the environmental benefits of the reusable container and gain additional marketing advantage, it is desirable to manufacture the container from recycled plastic, i.e. recyclates.

Some embodiments may include features that are attractive to consumers, such as longitudinal segments having engineered profiles, integral product markings, and/or indicia to encourage consumers to reuse the container and recycle the container along with other household plastics at the end of the container's life cycle.

In some embodiments, the indicia can include as logos, trademarks, advertising, instructions, directions, icons, symbols, or other markings. The indicia may be molded directly onto one or more of the longitudinal segments in relief to eliminate the need for printing and/or special treatments while increasing the durability of the container.

Although the invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiment to alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while several variations of the invention have been shown and described in detail, other modifications, which are within the scope of the invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of this specific features and aspects of the embodiments may be made and still fall within the scope of the invention. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of at least some of the embodiments of the present invention herein described should not be limited by the particular disclosed embodiments described above. 

1. A collapsible container for stackable items, comprising: a hollow cylinder of a resilient material, open at both ends, including at each end a retainer, the cylinder having a plurality of lines of weakness extending along at least a portion of the length of the cylinder such that the container is collapsible by application of a nominal force.
 2. The collapsible container of claim 1, wherein at least one of the retainers is a toggle retainer connected to the cylinder by first and second hinges.
 3. The collapsible container of claim 2, wherein at least one toggle retainer is comprised of at least two marginal portions interconnected by at least a third hinge.
 4. The collapsible container of claim 3, further comprising jambs adjacent the first, second and third hinges that are angled such that the marginal portions come to rest against the jambs simultaneously when the toggle retainers is moved into the closed position.
 5. The collapsible container of claim 1, wherein the retainer comprises a textured outer surface.
 6. The collapsible container of claim 1, wherein the resilient material is injection moldable.
 7. The collapsible container of claim 6, wherein the resilient material is a polypropylene.
 8. The collapsible container of claim 7, wherein the resilient material is a co-polymer polypropylene.
 9. The collapsible container of claim 1, wherein the lines of weakness extend the entire length of the cylinder.
 10. The collapsible container of claim 1, wherein the lines of weakness are longitudinal portions of the cylinder having a lesser thickness compared to cylinder portions adjacent to the lines of weakness.
 11. The collapsible container of claim 1, wherein the cylinder comprises a window.
 12. The collapsible container of claim 11, wherein the window is an opening in the cylinder between the open ends.
 13. The collapsible container of claim 1, wherein the nominal force is less than 12 ounces.
 14. The collapsible container of claim 1, wherein the cylinder comprises at least four said lines of weakness.
 15. The collapsible container of claim 1, wherein the cylinder comprises at least one offset portion to provide an internal channel and an external protrusion.
 16. The collapsible container of claim 15, wherein the offset portion extends substantially the entire length of the cylinder.
 17. A collapsible container for storage of one or more objects, comprising: a plurality of longitudinal segments interconnected by compliant hinges, the longitudinal segments and compliant hinges forming a loop; the loop having a passage extending between first and second openings, the loop having a first configuration permitting storage of objects within the passage and a second configuration wherein the cross-sectional area of the passage is reduced; and a retainer near each of the first and second openings, each retainer having an open position to allow objects to pass through one of the first and second opening into the passage and a closed position to inhibit movement of objects within the passage from moving out of the passage.
 18. The collapsible container of claim 17, wherein at least one of the retainers is a toggle retainer connected to the cylinder by first and second hinges, the at least one toggle retainer being comprised of at least two marginal portions interconnected by at least a third hinge, the container further comprising jambs adjacent the first, second and third hinges that are angled such that the marginal portions come to rest against the jambs simultaneously when the toggle retainers is moved into the closed position.
 19. The collapsible container of claim 17, wherein the retainer comprises a textured outer surface.
 20. The collapsible container of claim 17, wherein at least one of the longitudinal segments comprises a window.
 21. The collapsible container of claim 17, wherein the collapsible container comprises at least four longitudinal segments.
 22. The collapsible container of claim 17, wherein at least one of the longitudinal segments if offset from the adjacent longitudinal segments at the compliant hinges to provide an internal channel and an external protrusion. 